三维打印燃气轮机熔模铸造陶瓷芯的经济性

IF 4.2 Q2 ENGINEERING, MANUFACTURING
Eduardo Maristany , Zachary C. Cordero , Jesse Boyer , Lynnora O. Grant
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引用次数: 0

摘要

近期影响机翼铸造业的供应链问题再次激发了人们对陶瓷芯材工业级三维打印的兴趣。陶瓷型芯的传统制造方法是注塑成型。然而,小批量生产的注塑成型具有挑战性,因为与模具相关的交付周期长、成本高。三维打印可以降低前期模具成本,但也有其他折衷方法,例如,三维打印原料的材料成本较高。在此,我们开发了一个技术经济模型,该模型考虑了成本(材料、模具、设备)、型芯尺寸、经验曲线效应和其他重要变量,以确定 3D 打印成本低于传统加工技术的临界产量。利用 2019 年的市场数据,我们的分析表明,在低于 1800 件的情况下,3D 打印具有航空发动机应用典型尺寸的单个专用型芯设计的成本低于注塑成型。如果同时打印多个型芯设计,这一临界值将增加到 120,000 件,约占 2019 年航空发动机市场需求的 2%。这一临界值随着型芯尺寸的增大而减小,表明3D打印对工业燃气轮机中使用的大型铸件不太有利。这些结果与发动机开发、发动机维护和新发动机制造中对陶瓷型芯的需求进行了比较。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Economics of 3D printing ceramic cores for gas turbine investment castings

Recent supply chain issues affecting the airfoil casting industry have renewed interest in industrial-scale 3D printing of ceramic cores. Ceramic cores are conventionally manufactured through injection molding. However, injection molding of low-volume production runs can be challenging because of the long lead times and high costs associated with mold tooling. 3D printing can mitigate up-front tooling costs, but there are other trade-offs, e.g., higher material costs of 3D printing feedstocks. Here, we develop a techno-economic model that accounts for costs (materials, tooling, equipment), core size, experience curve effects, and other important variables to determine threshold production volumes for which 3D printing is less expensive than conventional processing techniques. Using market data from 2019, our analysis shows that 3D printing a single dedicated core design with typical dimensions for aeroengine applications is less expensive than injection molding below ∼1,800 units. By simultaneously printing multiple core designs, this threshold increases to 120,000 units, or approximately 2 % of the 2019 aeroengine market demand. This threshold value decreases with increasing core size, indicating 3D printing is less favorable for large castings used in industrial gas turbines. These results are compared against the demand for ceramic cores in engine development, engine sustainment, and new engine manufacturing.

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来源期刊
Additive manufacturing letters
Additive manufacturing letters Materials Science (General), Industrial and Manufacturing Engineering, Mechanics of Materials
CiteScore
3.70
自引率
0.00%
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0
审稿时长
37 days
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